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On the other hand, high viscosity, or high resistance to flow, can Overall efficiencies of hydraulic components are related to
result in sluggish operation, along with decreased mechanical mechanical efficiency and volumetric efficiency. Mechanical
efficiency. Energy losses from high viscosity can result in elevated efficiency is related to frictional losses and drag due to fluid
fluid temperature. High viscosity can cause cavitation and poor air viscosity, and volumetric efficiency relates to internal leakages.
release properties, resulting in cavitation and aeration erosion, as Both volumetric and mechanical efficiencies depend on the viscosity
shown in Figure 2. In addition, lubricants may not reach areas with of the fluid. As shown in Figure 4, volumetric efficiency increases
tight clearances, causing failures due to inadequate lubrication. with increased viscosity and mechanical efficiency increases with
decreased viscosity. The particular range of viscosity at which
overall efficiency is maximum is typically selected as the optimum
range for the specific components. Viscosity recommendations
should be considered for all system components, but viscosity
recommendations for pumps and motors should be given prime
importance.
Volumetric efficiency
Pump efficiency
Mechanical efficiency
Optimum
Figure 2. High viscosity can lead to cavitation and erosion operating range Overall efficiency
caused by a collapsing air bubble or vacuum bubble.
Viscosity
The rate of air release varies based on different viscosities and
temperatures. At a given temperature, air is released faster with Figure 4. The optimum operating range of a hydraulic system
lower viscosity fluids, as shown in Figure 3. As the temperature depends heavily on fluid viscosity.
increases, air is also released faster for each fluid.
Anti-wear (AW) properties of fluids are another crucial parameter
to be considered. Good AW properties are required to maximize
20 hydraulic system performance and component life. The fluid must
be properly formulated and have adequate AW additives. The AW
Air release value (minutes)
ISO VG 32
10 additives form a thin layer on the mating surfaces and help
prevent metal-to-metal contact at boundary lubrication conditions.
5 ISO VG 46 The resulting damages due to lack of AW properties is
depicted in Figure 5.
2
ISO VG 68
1
ISO VG 100
0.5
20 30 40 50 60 70 80 90
Temperature(C)
2 EATON www.eaton.com
Selecting fluids for hydraulic pumps White Paper
Effective August 2016
Insufficient AW properties can lead to cold welding and scuffing The Eaton-Vickers 35VQ25 pump test was developed to
in the boundary lubrication regime, resulting in removal of surface demonstrate a fluids ability to protect components from wear,
material. Anti-wear properties are essential for both rolling and thereby confirming long-term use in various operating conditions, as
sliding contact, but the requirement for sliding contacts is more shown in Figure 7. The test was adopted by the American Society
critical, as stick-and-slip type movement can occur. Even the best for Testing and Materials (ASTM) with the designation of ASTM
machined surfaces have asperities (hills and valleys). When the D6973 (Standard Test Method for Indicating Wear Characteristics of
asperities come in contact at heavy load, they can become joined Petroleum Hydraulic Fluids in a High Pressure Constant Volume
by cold welding. If the applied force is large enough to break the Vane Pump).
welding, the object suddenly moves. This causes material removal
from surfaces. High additive reserve is recommended for severe
applications, to allow the surfaces to slide or roll over each other
without any surface damage, as shown in Figure 6.
5000
Total wear(mg)
4000
3000
2000
1000
0
Figure 6. Anti-wear additives can help surfaces slide over each 0 200 400 600 800 1000 1200 1400 1600
other and avoid stick-and-slip movement. Time on oil (hours)
EATON www.eaton.com 3
White Paper Selecting fluids for hydraulic pumps
Effective August 2016
Other properties to consider include: area, get heated up due to compression, and carbonize oil at the
Viscosity Index (VI) - Empirical, unit-less number indicating bubble interface, resulting in carbon byproducts and oxidation. Air
the effect of temperature change on the kinematic viscosity release characteristics have more significance in systems with
of an oil. Liquids become less viscous when heated. A high VI relatively short residue time. An air-release test can identify the
indicates a relatively small change of viscosity with temperature. ability of a lubricant to separate entrained air.
High VI (multi-grade) fluids are recommended for applications Foaming tendency - Foaming is a common problem for
at wide operating temperatures or at extreme environmental hydraulic systems. Large volumes of foam can cause overflow
conditions. In general, high VI fluids are recommended for mobile of reservoirs. Factors that lead to foaming are contamination,
applications, as they are exposed to environmental changes and degraded fluid, air entrainment, and poor system design. Hydraulic
high operating temperatures. fluid formulations contain foam inhibitors, but very higher dosages
Shear stability - This is the measure of a fluids resistance to can give adverse effect. Foaming tendency test describes the
shearing. Polymers known as VI improvers are used to make high volume of foam generated immediately after the fluid is agitated
VI fluids. The molecules of VI improvers break down to smaller and aerated. Foam stability measures the volume of foam
molecules, causing thinning of viscosity, also known as shearing. remaining after a specific time from the stoppage of aeration.
Shear stability is the most important property of a VI improver. Volatility - Volatility is the tendency of a fluid to vaporize rapidly.
VI improvers with low shear stability will quickly break down, While generally not as critical for hydraulic fluids as for motor
resulting in thinning of oil. Viscosity after shear also needs to be oils due to limited or no exposure to high temperatures and
considered for applications with VI improved fluids. lower operating temperatures of hydraulic fluids, volatility is
Thermal and oxidative stability - Oxidation is chemical reaction still a parameter to consider. Mineral base oils are mixtures of
of oxygen with oil, generating acidic byproducts. The rate of hydrocarbons of different size. At high operating temperatures,
oxidation is accelerated by high temperatures, water, acids smaller molecules may escape from the oil, decreasing oil volume
generated due to oxidation, and presence of metal catalysts and increasing fluid viscosity. Improper base oil selection and
such as copper. The rule of thumb is: oxidation doubles with blending can lead to higher volatility.
increase of temperature by every 10oC. Oxidation will lead to
increased viscosity, total acid number (TAN), generation of varnish How to Select the Right Fluid
and sludge, and darkening of fluid. The rate of oxidation can be A properly selected fluid meets the requirements of the various
reduced by reducing fluid temperature and using fluids formulated properties mentioned above in a balanced manner. Because
with quality base stocks, anti-oxidant additives, and thermally identifying and interpreting all fluid requirements for a common
stable AW additives. user is difficult, Eaton has developed a full-fledged specification
Hydrolytic stability - Hydrolysis is chemical degradation of that cover requirements of hydraulic fluids and stipulate base stock
lubricants by reaction with water. Lubricant additives, especially requirements, physical properties, and performance requirements for
zinc-based additives, will react with water, forming acidic both conventional and zinc-free hydraulic fluids, along with material
by-products. The presence of metals such as copper can act as compatibility with rubber materials. Fluids meeting this specification
a catalyst. Ester-type base stocks also hydrolyze in presence have been considered good quality hydraulic fluids[2]. Most oil/
of water. Lubricants with good hydrolytic stability will resist additive manufacturers follow Eatons specification and print the
hydrolysis. same on their catalogs and on oil containers, so that the common
Filterability - Fine filters used in hydraulic systems may exhibit users can identify quality lubricants easily.
premature filter plugging due to inappropriate formulations, water Eaton has developed fluid recommendations with for Eaton hydraulic
contamination, and fluid degradation. Measurement of filterability products, such as Hydraulic Fluid Recommendations, which
helps predict fluid behavior in filtration applications, before use in provides basic guidelines for selecting hydraulic fluid. The document
a system. provides viscosity recommendations and cleanliness requirements
Demulsibility - The ability to release water from a water-oil for Eaton hydraulic products[3].
mixture. This characteristic is important for the equipment Numerous lubricants other than conventional hydraulic fluids are
operating in humid climates, where the possibility of water used in hydraulic systems, such as motor oil, automatic transmission
contamination is high. fluids, universal tractor transmission oil (UTTO), and super tractor
Rust and corrosion inhibition - Hydraulic fluids are generally oil universal (STOU). Some of these are formulated with mineral/
formulated with rust and corrosion inhibitors. The rust inhibitors petroleum-base oils, while others are synthetic-base such as those
get deposited as thin film on the metal surfaces and enable using a polyalphaolefin (PAO) base. Most Eaton components are
protection from rust. The corrosion additives hinder hydrolysis rated with these fluids
and prevent formation of acidic materials which causes corrosion. While hydraulic pumps are generally designed to operate with
The ability of a fluid to prevent rust and corrosion can be mineral-base fluids, alternative fluids are sometimes used for
measured by a rusting test using distilled water, salt water, applications where certain special properties are essential, perhaps
and a steel specimen. even more important than hydraulic system performance.
Material compatibility - Different rubber and elastomer For specific applications such as environmentally friendly and fire-
components, including hoses, accumulator bladders, seals, resistant applications, certain alternate fluids such as phosphate
and gaskets, are used in hydraulic systems and have different esters, polyol esters, polyether polyols, polyalkylene glycols,
compositions, or recipes. Because of these varying compositions, vegetable oil base fluids, water glycol, and invert emulsions, are
fluids are tested for their compatibility with most commonly sometimes used. For example, if fire resistance is critical, fire-
used elastomers to predict the life and performance with that resistant properties may be the most important factor. Similarly,
particular fluid. in environmentally sensitive applications, the focus may be on
Air release - Suspended entrained air can cause many biodegradability and toxicity. Other fluid types, such as food-grade
abnormalities such as poor system efficiency, system failure fluids and military specification fluids, are sometimes used in
through erosion (similar to cavitation), and fluid degradation hydraulic applications.
through micro-dieseling. Micro-dieseling occurs when air bubbles
move from a low- or negative-pressure area to a high-pressure
4 EATON www.eaton.com
Selecting fluids for hydraulic pumps White Paper
Effective August 2016
Each alternative fluid may have certain advantages for the specified A single issue can cause catastrophic failure. For example, poorly
application, but their fundamental properties, such as lubrication, maintained systems may fail catastrophically due to one or more
coefficient of friction, pressure viscosity coefficient, vapor pressure, reasons. Contamination, along with incompatible fluids, can lead
specific gravity, and low temperature properties, may not be to component failures, as shown in Figure 10. Any undesirable
equivalent to those of mineral-base lubricants. Therefore, hydraulic matter in the fluid is a contaminant and could be particulate matter,
components, especially pumps and motors may need to be de-rated water, air, or other lubricants. The Eaton document The Systemic
to account for these adverse factors. Approach to Contamination Control provides more information on
To determine whether a special or alternative fluid is warranted, contamination and its control[1].
ask some key questions, such as:
Is the hydraulic application near an ignition source or high
temperature surfaces, where fluid leakage could cause a fire?
Are fire suppression measures potentially ineffective or
impractical?
Would a fire result in unacceptable impacts or costs?
Are there any insurance benefits to using a fire-resistant fluid?
Does the system work in an environmentally sensitive area, such
as agriculture areas or forests, or where environmental regulations
are applicable?
Does the system need to be operated near or within waterways
such as rivers, canals, or oceans or water sources, such as dams
and reservoirs?
Could leakage of oil cause damage to the environment, which
could be a punishable offense?
Does the application have any non-standard requirements such as Figure 10. Contamination, lack of lubrication, and material
military or aerospace? incompatibility contributed to the failure of this piston shoe.
If the answer is yes to any of these questions, the system may
require a special fluid.
Summary
Impacts of Using the Wrong Fluid Key points to consider when selecting fluids include the
following:
What happens if an improperly matched fluid is used in a pump?
The answer can vary, depending on the degree of mismatch. Select an appropriate viscosity grade to ensure that the
As noted earlier, fully formulated fluids should have balanced fluid viscosity at operating temperatures meets viscosity
properties. Excessive variation in any given parameter can cause recommendations of the components, particularly for pumps.
direct or indirect impacts. For example, a fluid incompatible with Fluids must pass Eaton 35VQ25 pump test and satisfy Eaton
certain rubber materials may cause failure of gaskets and other E-FDGN-TB002-E fluid specification requirements.
components, as shown in Figure 9. Follow Eatons established pump ratings for applications with
alternate fluids.
With the proper fluid selection and adequate contamination
control practices, end users can achieve reliable operation of
pumps for many years.
Do not assume that a new hydraulic oil is clean; it could be
contaminated.
Transfer oil to hydraulic system reservoir only through filter carts.
Do not mix the fluid with any other type/brand/viscosity grade
fluid, as it may cause gelation, additive precipitation, miscibility,
filter blockage, and viscosity change.
Clean and flush hydraulic system including reservoir if any
component fail catastrophically. The particles generated may
damage other components.
Isolate contamination-sensitive components before flushing the
hydraulic system.
Figure 9. Rubber gasket extruded due to excess elongation Contamination limit should be maintained throughout the fluid life.
caused by incompatible fluid. Select filter ratings based on the system cleanliness
requirements.
Flush the system with the fresh fluid, even after cleaning the
system manually.
For changing to a different type fluid, clean the system thoroughly,
and flush with the fresh fluid to avoid any contamination with the
previous fluid used.
EATON www.eaton.com 5
White Paper Selecting Fluids for Hydraulic Pumps
Effective August 2016
With all the properties to consider, fluid selection may seem like a About Eaton
daunting process. For assistance, contact your Eaton representative Eaton is a power management company with 2015 sales of
or Eatons lubricant specialist for pump/motor ratings with different $20.9 billion. Eaton provides energy-efficient solutions that
alternate fluids. As an additional resource, the Eaton Lubricant Help help our customers effectively manage electrical, hydraulic and
Desk can offer assistance in defining fluid requirements, identifying mechanical power more efficiently, safely and sustainably. Eaton has
available documentation, and other technical support. approximately 97,000 employees and sells products to customers
in more than 175 countries.
For more information, visit www.eaton.com.